Manifold assembly for resin infusion and injection

ABSTRACT

A manifold for resin application, infusion, and/or injection is provided. The manifold comprises at least one inlet and a plurality of outlets. At least one outlet of the manifold comprises a valve that is operable to selectively dispense or terminate a flow of a resin from the outlet, and wherein the resin is supplied through the at least one inlet.

This U.S. Non-Provisional patent application is a Continuation of andclaims the benefit of priority from U.S. Non-Provisional patentapplication Ser. No. 15/632,062, filed Jun. 23, 2017 and now issued asU.S. Pat. No. 10,252,445, which claims the benefit of priority from U.S.Provisional Patent Application Ser. No. 62/354,472, filed Jun. 24, 2016,the disclosures of which are hereby incorporated by reference in theirentireties.

FIELD

The present disclosure generally relates to methods and devices forinjection of resins and similar materials. More specifically, thepresent disclosure relates to a system comprising a manifold forinjecting and controlling the injection of resins. Systems of thepresent disclosure comprise a plurality of flow ports for the controlledapplication and dispensation of a resin or similar material into a mold,a structure, a part, or a similar item.

BACKGROUND

Vacuum assisted resin transfer molding (VARTM) and related processes andtechniques have been widely used to fabricate relatively largefiber-reinforced composite articles. Such articles include articles ofvarious sizes including turbine blades, ship hulls, etc.

U.S. Pat. No. 6,216,752 to Bailey, which is hereby incorporated byreference in its entirety, discloses a gravity feed resin distributionsystem. Proper application of resin is important for avoidance ofstructural weaknesses and deficiencies of the resultant article. Bailey,however, fails to disclose various novel features of the presentdisclosure, as shown and described herein.

SUMMARY

There exists a long-felt and unmet need in the art for an improveddevice for enhancing and simplifying resin distribution in comparison tothe prior art. In various embodiments of the present disclosure,manifold assemblies, devices, and methods of use thereof for resininfusion processes and similar operations are provided. In certainembodiments, valve-controlled pipe manifold assemblies are provided. Thevalve-controlled pipe manifold assemblies of the present disclosurepreferably comprise a plurality of outlet ports that lead to varyinglengths of hose to ensure even coverage and cure of the resin over therequired surface.

In certain embodiments of the present disclosure, a resin infusionand/or application process is contemplated. The resin infusion processcontemplates “pulling” at least one resin through a system or product byusing a negative pressure differential (i.e. vacuum). An internalpressure within an assembly or manifold may range from 3 to 10 mbars(mbar=one thousandth of a bar, the centimeter-gram-second system unit ofatmospheric pressure equivalent to 100 Pascal's.)

It will be expressly recognized that the present disclosure is notlimited to any particular resin, or the use of any particular resin. Invarious embodiments, however, it is contemplated that a resin is appliedat an approximate temperature of between approximately 30° Celsius andapproximately 50° Celsius, and preferably at about 39° Celsius (102°Fahrenheit) during an infusion process.

In preferred embodiments, a pipe manifold for resin application andinfusion processes is provided. The pipe manifold preferably comprisesstock aluminum, but may comprise various other materials, materials andcombinations thereof. Pipe manifolds of the present disclosure maycomprise various dimensions, sizes, and proportions based on a desiredapplication. In certain embodiments, however, it is contemplated that amanifold is provided comprising an aluminum body portion with athickness of approximately 1.50 inches and a width of approximately 2.00inches. Such body portions are contemplated as withstanding the stress(from vacuum pressure, for example) and heat associated with variousmolding operations while still providing a light-weight andcost-effective component. In various embodiments, manifolds of thepresent disclosure are contemplated for use as vacuum-assisted devices,wherein resin is moved through the manifold at least in part due avacuum force at the injection outlets. Various existing technologiesgenerally fail to provide the proper structure, heat resistance, etc. towithstand the demands of such processes and various components andfeatures as shown and described herein are provided as non-obvioussolutions to issues associated with prior art devices.

In one embodiment, a pipe manifold is provided comprising one inlet portand a plurality of outlet ports (e.g. 2-6 outlet ports). In anotherembodiment, a pipe manifold is provided comprising one inlet port andthree outlet ports. In certain embodiments, the ports of a pipe manifoldterminate in, or otherwise comprise, a male pipe thread, 0.75-14 NPT. Achannel or thruway for the pipe manifolds and related ports iscontemplated as being between approximately 0.25 inches andapproximately 1.50 inches in diameter. In preferred embodiments, thechannel is provided comprising a diameter of approximately 0.6875inches.

In one embodiment, a pipe manifold comprises a length of betweenapproximately 18 inches and approximately 40 inches, and preferably ofapproximately 23.75 inches. The manifold comprises an inlet port and anoutlet port, wherein the inlet port and the outlet port are collinearabout a longitudinal axis of the manifold. An additional plurality ofports are orientated transversely to the length of the part, along a1.50″ thick surface. The first outlet port is located approximately 3.25inches from an inlet end of the assembly, and the remaining transverseoutlet ports are spaced approximately 5.00 inches apart thereafter.

In one embodiment, a pipe manifold comprises a length of betweenapproximately 5.0 inches and approximately 20.0 inches, and preferablyof approximately 11.75 inches. An inlet port and the final outlet portare preferably collinear and spaced apart by the length of the part. Aremaining plurality of ports are orientated transversely to the lengthof the part, along a 1.50″ thick surface. The ports are each preferablyoriented substantially perpendicular to the inlet port and the outletport. The first outlet port is located 3.375″ from the inlet end of theassembly, and the remaining transverse outlet port is spaced 5.00″ fromthe first.

In various embodiments, methods of resin infusion are contemplated. Incertain embodiments, methods of resin infusion are performed thatcomprise the steps of: providing a manifold as shown and describedherein, positioning the manifold in a desired position, attaching linesor conduits to each of the inlet, outlets, and/or ports of the manifold,opening an inlet to the manifold and allowing resin to flow into themanifold, opening resin infusion ports as needed or desired and allowinga vacuum force to extract resin from the manifold, and applying a heatblanket to a part (e.g. turbine blade) to bake the applied resin. Incertain embodiments, manifolds of the present disclosure are provided asdisposable components which may be used for as few as one resin infusionor application process. In some embodiments, the step of positioning themanifold comprises mounting the manifold to a fixture, such as a rackassembly disposed above or proximal to a workspace or workpiece.

In various embodiments, resin infusion manifolds of the presentdisclosure are provided as moveable or translatable components. Certainapplications may require the movement of a resin application manifold asshown and described herein in order to evenly apply a resin or similarcoating over a large area (e.g. during manufacture of large items suchas ship hulls). Accordingly, embodiments of the present disclosurecontemplate providing a manifold on a track and providing the manifoldas a motor-driven unit that is controllable and moveable by a user in ata constant velocity over a given distance.

Although specific embodiments are disclosed herein, wherein manifoldscomprise various specific dimensions, it will be recognized that thepresent disclosure is not limited to such dimensions or to manifolds ofany particular dimension(s). Manifolds of the present disclosure may bescaled up or down and/or varied in proportion.

In some embodiments, manifolds of the present disclosure arecontemplated as comprising hand-held items that may be manipulated by auser. Additionally, or alternatively, manifolds of the presentdisclosure may be mounted to an additional structure or frame member.Manifolds and manifold features, such as valves, may be connected to anelectronic control unit to control features and operations of themanifold.

In certain embodiments, manifolds of the present disclosure comprise aplurality of ports, wherein at least some of the plurality of portscomprise a valve to allow flow control and to provide emergency shut offaccess should there be a failure somewhere in the system (for example).Valves for use with manifold ports of the present disclosure include,but are not limited to ball valves, gate valves, solenoid valves, globevalves, butterfly valves, and diaphragm valves. In certain embodiments,at least some valves comprise a ‘quick connect’ compression fittingattached to the valve in order to allow efficient installation of therequired inlet and outlet hoses. In various embodiments, at least oneinlet hose and at least one outlet hose is connected to a manifold. Theinlet and outlet hose(s) are affixed to compression fittings andpreferably comprise spiral wire reinforced PVC transfer hose. At leastone of an inlet hose and an outlet hose is connected to a reducer, whichis affixed to a smaller diameter hose that leads directly to an infusionorifice.

The Summary is neither intended nor should it be construed as beingrepresentative of the full extent and scope of the present disclosure.The present disclosure is set forth in various levels of detail in theSummary as well as in the attached drawings and the Detailed Descriptionand no limitation as to the scope of the present disclosure is intendedby either the inclusion or non-inclusion of elements, components, etc.in this Summary. Additional aspects of the present disclosure willbecome more readily apparent from the Detailed Description, particularlywhen taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the disclosedsystem and together with the general description of the disclosure givenabove and the detailed description of the drawings given below, serve toexplain the principles of the disclosed system.

FIG. 1 is a perspective view of a manifold assembly for resin injectionaccording to one embodiment of the present disclosure.

FIG. 2 is a bottom plan view of the manifold assembly according to theembodiment of FIG. 1.

FIG. 3 is a front elevation view of the manifold assembly according tothe embodiment of FIG. 1.

FIG. 4 is a section view taken at line A-A of FIG. 3.

FIG. 5 is a dimensioned bottom plan view of the manifold assemblyaccording to the embodiment of FIG. 1.

FIG. 6 is a perspective view of a manifold assembly for resinapplication or infusion according to one embodiment of the presentdisclosure.

FIG. 7 is a bottom plan view of the manifold assembly according to theembodiment of FIG. 6.

FIG. 8 is a front elevation view of the manifold assembly according tothe embodiment of FIG. 6.

FIG. 9 is a section view taken at line A-A of FIG. 8.

FIG. 10 is a dimensioned bottom plan view of the manifold assemblyaccording to the embodiment of FIG. 9.

FIG. 11 is a perspective view of manifold assemblies according toembodiments of the present disclosure.

FIG. 12 is a perspective view of a component of a resin infusion systemaccording to one embodiment of the present disclosure.

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary for anunderstanding of the disclosure or that render other details difficultto perceive may have been omitted. It should be understood, of course,that the disclosure is not necessarily limited to the particular systemembodiments illustrated herein.

DETAILED DESCRIPTION

FIGS. 1-5 depict a manifold 2 according to one embodiment of the presentdisclosure. The manifold 2 comprises a primary inlet 4 and a primaryoutlet 6 provided in opposing relationship and distributed by a lengthof the manifold. The manifold 2 comprises an elongate body portion 8extending between the primary inlet 4 and the primary outlet 6. Theelongate body portion 8 comprises a substantially rectangularcross-section as shown in FIGS. 1-5, but may comprise various othershapes. The manifold 2 of FIGS. 1-5 comprises four resin applicationoutlets 10 distributed along a length of the manifold 2. As used herein,the terms “application”, “infusion” and “injection” are usedsubstantially interchangeably with respect to resin. One of ordinaryskill in the art will recognize that the final delivery location ofresin will be determined by the specific process and article ofmanufacture for which the device 2 is used.

As shown in the cross-sectional view of FIG. 4, the manifold 2 comprisesa major channel 12 and a plurality of minor channels 14 for ejectingresin or similar materials from the resin application outlets 10. Anexterior portion 16 of the minor channels 14 preferably comprises malethreaded members. Various Figs., including FIGS. 4-5, are provided withdimensions to illustrate manifolds of certain embodiments of the presentdisclosure. It will be recognized, however, that no limitation withrespect to size, shape or proportions of the manifold(s) are providedherewith. It is contemplated that the size and proportions of themanifolds may be varied based on a described application or use in aspecific process, for example.

FIGS. 6-10 depict a manifold 2 according to another embodiment of thepresent disclosure. The manifold 2 of FIGS. 6-10 generally comprises thesame structure of the embodiment of FIGS. 1-5, but comprises two resininjection outlets 10. The numbering provided with FIGS. 1-5 is thus alsoused for FIGS. 6-10, with like numbers representing the same or similarcomponents as shown and described herein.

In various embodiments, a manifold 2 of the present disclosure comprisesat least one valve. In certain embodiments, a valve is provided inassociation with each of the resin application outlets 10. Auser-interface, such as a valve handle, may be provided on an upperportion or side portion of the elongate body portion.

The manifolds 2 of FIGS. 1-10 are shown and described as comprising aprimary inlet 4 and a primary outlet 6. It is contemplated, however,that the primary outlet 6 may also operate as an inlet for resin andsimilar material. Similarly, the primary inlet 4 may operate as anoutlet for resin.

FIG. 11 is a perspective view of manifolds 20 a, 20 b according toembodiments of the present disclosure. As shown, each of the manifolds20 a, 20 b comprises a primary inlet 24, a primary outlet 25, and aplurality of resin application outlets 34. The first manifold 20 acomprises two application outlets 34 a, 34 b. The second manifold 20 bcomprises four application outlets 34 a, 34 b, 34 c, 34 d. The first andsecond manifolds comprise elongate body portions 22 having differentlengths to accommodate the different number of application outlets.

As shown in FIG. 11, each of the primary inlet 24, the primary outlet30, and the injection outlets 34 a, 34 b, 34 c, 34 d comprise auser-operable valve 36. The valve(s) 36 may comprise various differenttypes of valves, including manual valves, solenoid valves, and othervalves. For example, the valves 36 of FIG. 11 may comprise any one ormore of a ball valve, a globe valve, a butterfly valve, a gate valve,and a diaphragm valve, for example. In preferred embodiments, each ofthe valves 26, 30, 36 comprises a handle 28, 32, 38 that are operable toselectively control a fluid or resin flow through the respective outlet.FIG. 11 depicts hand-operated devices according to embodiments of thepresent disclosure. Alternative embodiments contemplate the provision ofvalves that may be remotely controlled, such as one or more solenoidvalves that are operable to be controlled by a circuit and a remoteswitch, for example. Such embodiments are particularly well suited forapplications where it is undesirable, unsafe, or impossible for a userto manually operate valves.

As shown in FIG. 11, the outlets 24, 25, 34 comprise a nipple or fittingin fluid communication with a valve and an internal flow path of theelongate body portion 22. An inlet or outlet fitting 24 contemplated foruse with embodiments of the present disclosure is further shown in FIG.12. As shown in FIG. 12, the fitting 24 comprises a threaded portion 40that is operable to be secured or connected to a valve (for example).The fitting 24 further comprises a rasped or toothed portion 42 that isoperable to receive and secure a hose or piping (for example). A collar44 is provided that is operable to receive a wrench to tighten or loosenthe fitting. An inlet 46 and an outlet 48 are provided on opposing endsof the fitting 24. The fitting 24 may be provided at any one or more ofthe primary inlet 24, the primary outlet 25, and the injection outlets34 of FIG. 12. Fittings of the present disclosure are contemplated ascomprising polyvinyl chloride, but may be formed of various materials ofsufficient durability and heat resistance for resin injection moldingoperations.

Although various Figures comprise dimensions, it will be expresslyrecognized that these dimensions are provided to illustrate certainembodiments and no limitations with respect to these dimensions areprovided herewith. It is contemplated that manifolds of the presentdisclosure, including those shown in the Figures may be scaled up ordown, and/or may be varied in proportion.

While various embodiments of the system have been described in detail,it is apparent that modifications and alterations of those embodimentswill occur to those skilled in the art. It is to be expressly understoodthat such modifications and alterations are within the scope and spiritof the present disclosure. Further, it is to be understood that thephraseology and terminology used herein is for the purposes ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein aremeant to encompass the items listed thereafter and equivalents thereof,as well as, additional items.

What is claimed is:
 1. A resin application manifold comprising: anelongate body portion comprising a length and having a first end and asecond end, and wherein the elongate body portion at least partiallydefines a fluid flow path; an inlet provided at the first end of theelongate body portion; a first outlet provided at the second end of theelongate body portion; wherein the inlet and the first outlet areprovided collinear with one another; a plurality of resin applicationoutlets provided along the length of the elongate body portion betweenthe inlet and the first outlet, and wherein each of the resinapplication outlets are provided perpendicular to the inlet and thefirst outlet and comprise male threaded portions operable to receive avalve; a channel extending through the elongate body portion andproviding the inlet in fluid communication with the plurality of resinapplication outlets; wherein each of the inlet, the first outlet, andthe resin application outlets comprise a valve for selectivelydispensing a resin through the at least one of the plurality of resinapplication outlets.
 2. The resin application manifold of claim 1,wherein the valves comprise ball valves and/or wherein the manifoldcomprises a plurality of resin application outlets.
 3. The resinapplication manifold of claim 1, wherein the resin application outletcomprises a fitting with an inlet and an outlet and wherein the fittingis operable to receive at least one of a rubber hose and a pipe.
 4. Theresin application manifold of claim 1, wherein the fluid flow pathcomprises an interior channel having an internal diameter of betweenapproximately 0.25 inches and approximately 1.50 inches.
 5. The resinapplication manifold of claim 4, wherein the interior channel extendsbetween the primary inlet, the primary outlet, and the resin applicationoutlet.
 6. A resin application manifold comprising: a body portioncomprising a length and having a first end and a second end, and whereinthe body portion at least partially defines a fluid flow path; an inletprovided at the first end of the elongate body portion; a first outletprovided at the second end of the elongate body portion; a plurality ofresin application outlets provided on the elongate body portion betweenthe inlet and the first outlet; wherein each of the plurality of resinapplication outlets comprises a valve with a handle operable toselectively control a fluid or resin flow through the respective resinapplication outlet, and a fitting connected to the valve; wherein thefitting comprises a threaded portion that is operable to be secured tothe valve, a rasped portion that is operable to receive and secure ahose, and a collar that is operable to receive a tool; and wherein theinlet and the first outlet comprise a valve for selectively dispensing aresin through the at least one of the plurality of resin applicationoutlets.
 7. The resin application manifold of claim 6, wherein thevalves comprise at least one of a ball valve, a globe valve, a gatevalve, a solenoid valve, and a diaphragm valve.
 8. The resin applicationmanifold of claim 6, wherein the manifold comprises at least three resinapplication outlets.
 9. The resin application manifold of claim 6,wherein each of the resin application outlets comprises a polyvinylchloride fitting.
 10. The resin application manifold according to claim6, wherein the threaded portion and the rasped portion are provided onopposing sides of the collar.
 11. The resin application manifold ofclaim 6, wherein the body portion comprises aluminum.
 12. A resinapplication manifold comprising: a body portion comprising a length andhaving a first end and a second end, and wherein the body portion atleast partially defines a fluid flow path; an inlet provided at thefirst end of the elongate body portion; a first outlet provided at thesecond end of the elongate body portion; a plurality of resinapplication outlets provided on the elongate body portion between theinlet and the first outlet; wherein each of the plurality of resinapplication outlets comprises a valve operable to selectively control afluid or resin flow, and a fitting; wherein the fitting is operable toreceive and secure a hose, and a collar that is operable to receive atool; and wherein the inlet and the first outlet comprise a valve forselectively dispensing a resin through the at least one of the pluralityof resin application outlets.
 13. The resin application manifold ofclaim 12, wherein the valves comprise at least one of a ball valve, aglobe valve, a gate valve, a solenoid valve, and a diaphragm valve. 14.The resin application manifold of claim 12, wherein the manifoldcomprises at least three resin application outlets.
 15. The resinapplication manifold of claim 12, wherein each of the resin applicationoutlets comprises a polyvinyl chloride fitting.
 16. The resinapplication manifold according to claim 12, wherein the fittingcomprises a threaded portion and a rasped portion.
 17. The resinapplication manifold of claim 12, wherein the body portion comprisesaluminum.
 18. The resin application manifold of claim 12, wherein thebody portion comprises a rectangular cross-section.
 19. The resinapplication manifold of claim 12, wherein the each of the plurality ofresin application outlets comprise a compression fitting to allow forefficient installation of hoses.